Process and mold for forming earthenware articles and product thereof



Mar. ZZ; 1923, 1,449,762 c. J. KIRK ET AL. v

PROCESS AND MOLD FOR FORMING` EARTH-ENWARE ARTICLES AND PRODUCT THEREOF Filed Apr. e, 1922 F|G.4 F|G.5 l:7161.6

. NVEN ORS 1.14 .7 @L

Patented Mar. 27, 1923.

UNETEU STATES CHARLES J. KIRK AND GEORGE EEAIN, 0E NEW CASTLE, PENNSYLVANIA, ASSIGNOIES intatta Param* orties.

TO UNIVERSAL SANITARY MANUFACTURING CO., 0F NEWT` (`1 .l'.tS'I1 '.E,` PENNSYL- VANIA, A CORPORATION OF PENNSYLVANIA. I

PROCESS AND MOLD FOR FORMING' EARTHEN WARE ARTICLES PRODUCT vlIHIEIEtEOE'.v

Application sled April e,

To all whom t 'may concern.'

Be it lrnown that we, CHARLES J. KIRK and GEORGE BRAIN, citizens of the United States, and residents of New Castle, in .the county of Lawrence and State ot' Pennsylvania, havey invented a new and useful; Improvement in Processes and Molds for Forming Earthenware Articles and Product Thereo'; and we do hereby declare the tollowing to be a full', clear, and exact description thereof. Y

Our invention relatesto the art of forming earthenware articles, particularly cast porcelain waterclosets, and it constitutes an improvement over the invention set forth andclaimed in U. S. Let-ters Patent ,-No. 952,745 granted to Charles J. Kirk March 22,191.0. y

As .describedin PatentNo. 952,745, articles of plastic material having tortuous pas`r sages, such as closet bowls, are cast by inserting in the mold a previously formed permanent core which forms an integral part of the completed article; When closet bowls are thus cast,.the permanent core is of the Shape of the siphon member or" the bowlandj in the method Shown in Patent No.1,952,745 the lower wall of the Siphon channel is spaced from the front and bottom walls of the Siphon member. When such a castfbowl is removed vfrom the mold the porcelain is still Soft and if, during drying and setting, it is subjected to shocks or vibrations the lower wall of the Siphon channel is likely to sink into the opening between this wall and the front and bottom walls of thesiphon, thus spoiling the work.

Our present invention aims to improve the manufacture of cast .porcelain bowls of the character indicated by modifying the construction of the permanent coreor Siphon member so that the underside of the Siphon. channel-shall be supported by a vertical wall which strengthens the Siphon member and Specifically, we

1922. Serial No. 550,212.

ever, that the preciseshape and arrangement' of parts may loe varied toa considerable eX- tent. Fig. l is a side elevational view of the closet mold with one of the Side members removed, showing the permanent core and base ring in place; Fig. 2 is a longitudinal vertical sectional view taken centrally through the mold showing the mold illed with the liquid slip; Fig.v 3 is a perspective View Vof the permanent core or Siphon member Fig.

et is an end elevational view of the Siphon member of Fig. 3;.Fig. isaivertical sec tional view through the -siphon member, the Section being taken substantially on the eov line 5 5, Fig. l; and Fig. 6 is a vertical'sec-l portion 2, and a circular aperturel 3 is provided through the base "block for the discharge opening of the closet Siphon. The upper Surface of the base block at this point is provided'with a concentric circular por;y tion 4, slightly raisedand of less diameter thanxthewi-dth of the base of the inished. article. The remaining upper surface ofthe` finished block is provided with a Separate raised portion 5. The outer contour ofthe closet is formed byla mold centrally divided intotwo Vremovable halves 6. The inner upper surface 7 of "the bowl is formed by a de? pending member 8 carried .by the top' block .9. The top block is provided with a `tunnelshaped aperture 10 which opens through the lower' extremity of the bowl-forming mem-l ber 8. The top bloc-k is also provided 'with' `a depending Semi-circular memberllpro-v aoy liecting vcent'rallyfrom one end of ,thefbowlrf' forming member 8 and received ina corre,

spondinglysh'aped recess 12in thewalls of' i the mold members 6. A base ringv 13 and a previously formed permanent core or Siphony `member 14 are placed in the positionishown in Fig. l upon the base block. The base ring 13 corresponds in diameter to the circular raised portion t of the base block and is provided withan aperturecoinciding aperture 3 through the base block.

The Siphon member 141, is of the form best with the n Aio shown in Figs. 3 to 6. lt. consists of a base member 15, a ront wall 16 and sides 17 which extend upwardly as shown at 18 to join the upper end of the Jfront portion 16. A vertical web 19 supports the rear portion of the receptacle formed by the wall 17, and another vertical web 20 is formed in the triangular space between the base 15, the front portion 16 and the inside of the receptacle or channel member formed by the side walls 17. The base 15 is of the hollow curved construction shown in Figs. 4, 5 and 6, and the front member 16 is also made hollow, as shown in Fig. 4.

The base ringk 13 and the Siphon member 14 are 'cast Separately and preferably from the same material as is used in the casting of the closet, or from some other material which will contract at about the same rate during the setting and firing operations. The base ring and the Siphon member are placed in the mold while they are still sott, in order that they will readily adhere to each other and to the slip. The mold is then iilled with liquid slip which enters all of the spaces between the'sides of the Siphon member, the base ring, the bowl-forming member 8 and the side members 6 of the mold. After the slip has been allowed to set for a suilicient length of time a deposit 30 of porcelain 'forms upon the inner sides of the mold and envelopes the Siphon member, as shown in Fig. 2. When this deposit is of the proper thickness, the closure 21 is removed from the discharge opening 3 in the base block, and the remaining liquid is drawn off, leaving the completed closet bowl with its Siphon passages and base member, and ,with the Siphon member or core embedded in place. The top block with the depending bowl forming member 8 is then removed, carrying away the vdeposit 31 onl the upper surface of the member 8, and the flushing ring is attached in the usual manner, after which the porcelain is set and fired.

Fig. 6 shows a section of the completed article on the line 6-6, F 1. It will be observed that the side walls 17 of the channel portion of the Siphon member are united integrally with the vertical side walls 32, and also with the base portion 15 or" the Siphon member.

During the period of setting, the entire structure, including the Siphon member 14, is still soft, but the webs 19 and 2O prevent the walls of the Siphon channel to sink, even though the article is subjected to considerable shock or vibration. Ve have found that the loss o1" ware through damage of thiskind is entirely eliminated.

A further advantage of this method is that a better union is produced between the permanent core or Siphon member and the enveloping walls of porcelain, inasmuch as the porcelain isdeposited in the recess adjacent to the webs 19 and 20 and upon the webs themselves.

`We claim as our invention:

1. The process of forming a closet of cast earthenware which comprises providingl a Siphon member forming the top of the discharge arm of the Siphon and the bottom or' the intake arm of the Siphon, the said member having the intake Siphon portion supported throughout its length upon said discharge portion by means of a solid web, placing the said siphon member in a mold, forming the exterior oi' the closet bowl, and

casting the said Siphon member within the closet.

2. The process of forming a cast porcelain closet that comprises providing a Siphon member, forming the inner suriace of the siphon passageway, and having said surface portion supported from beneath throughout its length by means of a solid web, placing said Siphon member in a mold conforming to the outer surface of the closet bowl, and casting said Siphon member wit-hin the closet.

3. In a mold for casting Siphon closets, the combination with top, side and bottom members conforming to the outer surfaces of the closet, of a core or Siphon member of substantially the same material as the closet conforming to the interior Surfaces of the Siphon walls, and having its upper portion which forms the lower wall of the Siphon channel supported from beneath throughout its length by means of a solid web, the said Siphon member being supported upon said base member and being adapted to be covered with a deposit of porcelain and to form a homogeneous part of the completed closet.

4. In a mold for castingV Siphon closets,l the combination of top, side and bottom members conforming-.to the outer surfaces of the closet, of a permanent core or Siphon member of substantially the Same material the closet conforming t'o the 'bottom of the intake arm and the top of the discharge arm of the Siphon, the said intake portion being supported upon said discharge portion by means of a solid web joining said portions, and said Siphon member being supported upon said base member and being adapted to be covered with a deposit of porcelain and to form a homogeneous part of the closet.

5. A permanent core or Siphon member for use in casting earthenware closets comprising a base member, a channel member supported upon said base member, and solid means Jformed integral with said members for supporting said channel member upon said base member.

6. A permanent core or Siphon member for use in casting earthenware closets comprising a hollow base member, a channel sie ` pleted closet, a front portion connecting the member supported upon said base member, and a solid web portion east integral with said base and channel members for supporting the insideV of said channel member.

7. AA permanent core or Siphon member for use in casting earthenware closets comprising a base member, a channel member supported on said ibase member and having an upward extensionv forming the under side of the intake arm vof the Siphon in the eomsaid extension and said base member, and a solid web formed integral with vsaid base member, front portion and channel member, and serving to support the under side of said channel member. y

8. A permanent vcore or Siphon member for use in casting earthenware elosets'eom-v prising a base member, a channel member supported on said base member and having an upward extension forming the under side of vthe intake arm of thesiphon in Vthe completed closet, va frontportion eon necting` the said extension and Said base member, a web formed integral with said base memlber, front portion and channel member, and serving to support the under side of said `channel member, and a second vweb integral with said spaced portion and channel member for supporting the rear portion of said channel member.

` 9. A cast porcelain Siphon vcloset having a Siphon portion comprising two spaced parallel walls and a Siphon member `disposedbetween said walls, saidmember having a downwardly -eurvedjupper portion forming the under sideV of the Siphon intake channel, and an upwardly 'curved base portionlforming the upper side of the Siphon discharge ehannel,.the said upper and lower portions or' said Siphon member being integrally united to each other and to said side walls. v y

In testimony whereof, we y the said CHARLES'J. KIRK and GEORGE BRAIN have hereunto Set our hands.

CHARLES J. KIRK, GEORGE' BRAIN.

Vitnesses: i

MONT L. AILEY, TvVrrI'r'rAKER. 

